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Internship Report :Dawn Bread

Sana Mehboob
Roll No. 06 (Regular)
B.Sc. (Hons.) Food Science & Technology

Institute of Food Science & Nutrition.

University of Sargodha, Sargodha.
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INTERNSHIP REPORT

DAWN BREAD

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 Internship Report Outline

• Introduction to industry • Cake Hal

• Functions of departments
• Burger hall
• Vision and mission
• Bread section
• Objective and quality
• Friction factor
statement
• Bread baking problems
• Swot analysis of dawn bread
• Suggestions
• Baking ingredients and their
functions
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Products Of Dawn Bread

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 Introduction

• Dawn bread establishment of plant

City Year
Karachi 1981
Islamabad 1985
Hyderabad 1987
Lahore 1987
Multan 1989
Faisalabad 1992
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 Vision and Mission Statement
 Dawn Bread with a vision to exceed the expectations of consumers
 With great taste products that delivers convenience, quality, safety
and value
 Dawn bread is undoubtedly market leader in fresh baked bakery
products
 “To provide quality products to customer and explore new markets
to expand sales of the company through good Governance and
dynamic team
 So as to achieve Optimum price of products of the company for
sustainable and equitable Growth and prosperity of the company”
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 Objectives and Quality Policy

 Objectives
• Dawn Bread’s longstanding commitment toward consumer
satisfaction is evident and initiation of bringing Pakistan the
world’s most technologically advanced baking units and
processes
 Quality Policy
• We work together as a team for implementation and continual
improvement of total quality system in order to achieve
satisfaction of our internal and external customers 8
 Continue…
• ISO 9001: 1994 certified in 2000
• Established yeast plant at Lahore
• Halal certified
• Supplier of McDonald’s hamburger
• KFC (Kentaccy fried chickens)
• Hardees
• Dunkin donuts
• Avari Lahore
• Pearl continental
• Subway
• Hot dog
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 Continue…
 Comprises of
 Group of private limited companies
 Group members based on food products
Bread and beyond
Dawn mayo
Dawn foods
Dawn bread
Dawn maizban

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 Nature of Organization Continue…

 Dawn bread  Dawn foods

• Breads • Ready to eat

• Burgers • Zinger

• Buns • Koofta
• Aloo Paratha
• Rusks
• Wings
• Cakes
• Chicken Patties
• Biscuits
• Chicken rolls

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 Nature of Organization Continue…

 Dawn mayo  Dawn maizban

.
• Chili and soya sauce • Chicken chapli kebabs
• Chicken spread • Chicken mallei boti
• Mayonnaise • Chicken samosa
• Tomato ketchup • Chicken spring roll
• Chili garlic • Chicken seekh kabab
• Sauce vinegar • Chicken shami kabab
• Tomato sauce • Vegetable spring roll
• Ginger & garlic paste 12
 Bread and Beyond

 Dawn foods has various brands

 Bread and beyond one of them

 Daughter company of dawn bread

 Have more than 200 products

 Acutely aware of the needs for appealing

products (confectionery and bakery products)
 Satisfying customer

 Backbone of dawn bread

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 Continue…
 Competitors

Gourmet City bread

Bunny’s Mary gold
Cakes and bakes Morgan bread
Bake parlors Wonder bread

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 Swot Analysis of Dawn Bread
 Strength
Holding 35% shares of bread in Pakistan
Largest distribution network
Advance production units
Effective on time delivery
Vast range of quality
Vast range of products with variety of flavors
Stability of production
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 Swot Analysis (Continue…)

 Weakness
No quality control labs
No proper medical facilities
Hygiene and sanitation issues
No proper research laboratories
Over work burdens on employers
Large product range lacking proper planning
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 Swot Analysis (Continue…)
 Opportunities
Innovation in product
Product quality
Growing varieties in RTE food
To create the awareness among customers about new
products
To increase the skilled labor

Use motivational techniques regarding employees 17

 Swot Analysis (Continue…)

 Threats
More manual work
Trade discounts offered by competitors
Lack of implementation of quality standards
Lacking bench marking and re-engineering
High affinity to better/new image brands
Some products loose focus, due to new brands
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Baking ingredients and their functions

1. Flour
• Largest single component of bread

• Reduced form of endosperm (particle size 140 mµ)

• Powdery substance produced by finely grinding grain
through milling
• Patent (white) flour is used
• Gelatinizing capacity
• Contain essential amino acids except lysine
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 Flour continue….

 Classification based on amount of protein

 Protein determines gluten strength of flour

 Gluten gives the dough its shape and form

• Bread flour (9-13% gluten content, used for bread

making)
• Cake flour or soft flour (< 7 % gluten content )

• All purpose flour (medium gluten strength, suitable for

any baking purpose)
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Quantitative Analysis Of Flour

Component %age
Protein 11-12%
Fat 0.3%
Fiber 0.6%
Minerals 0.5%
Sugar 2.5%
Starch 70%

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 Characteristics Of Flour

• Water absorption
• pH (5.5-6.5 )
• Color ( creamy white )
• Uniformity ( uniform particle size )
• Flour strength ( according to product)

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 Constituents of Flour

 Starch
 Important carbohydrate in flour

 About 70% in bread making flour

 Dilute gluten

 Provide strong union with gluten

 Become flexible by gelatinization

 Moisture 14-16%

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 Flour constituents (Continue… )

 Protein
• 8-10% in soft wheat flour
• 12-14% in hard wheat flour
• >16% in extra hard wheat flour
• 4 types of protein in flour

Albumin
Globulin
Gliadin
Glutenin
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Baking Ingredients (Continue…)

Others are
 Water
 Eggs
 Leavening agent
 Sugar
 Fat
 Shortening agents and emulsifiers
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 Baking Ingredients (Continue…)
 Water
 Basic ingredient
 Solvent for the dispersion of salt, sugar and other ingredients
 Hydration of protein to form gluten

 Controls the consistency of dough

 Controls the dough temperature

 Make enzymes activities possible

 Amount varies according to the product

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 Baking Ingredients (Continue…)
 Sugar
 Table sugar or sucrose
 Major ingredient in baking
 Amount varies according to the product

 Serves as nutrient for yeast in fermentation

 Retains moisture and prolong freshness

 Improves flavor

 Improves grain and texture of bread

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 Baking Ingredients (Continue…)
 Shortening Agents and Emulsifiers
 Type of solid fat, made from vegetable oils, such as soybean
and cotton seed oil
 It shortens gluten strands in wheat by adding fat

 To obtain improved slicing properties as well as extra softness,

tenderness
 Example are butter and margarine

 Increases the nutritive value

 Assists in gas retention, thus giving better volume and crust.28

 Baking Ingredients (Continue…)
 Leavening agents
 Yeast and baking powder
 Leavening dough by CO2 production
 Types of yeast

 Living Yeast
 Baker’s Yeast
 Dead Yeast

 Flavoring and fermentation purpose.

 Give structure to the product
 Acetic acid and lactic acid produced, give flavor to the product
 The ideal temperature is 26-30°C
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 Baking Ingredients (Continue…)
 Salt
 Used for taste and toughens the gluten
 Effect on color and keeping quality
 Controls the activity of yeast (fermentation)

 Decreases the stickiness of dough

 Salt should have the following characteristics.

i. Completely soluble in water.

ii. Pure, give a clear solution.
iii. Free from bitter/ bad taste and lumps
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 Baking Ingredients (Continue…)
 Eggs
 Binders, holding ingredients together

 Whole eggs and yolks contain emulsifiers that distribute

fat in the batter
 Provide coagulated structure, color, flavor
 Egg whites contribute aeration and leavening when beaten
due to the presence of air cells that are filled with CO2
 Egg proteins contribute to the structure
 Play an important part in nutrition
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 Internship Areas
 Following areas:
Cake hall
Production hall
Burger section

Bread section

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 Cake Hall
Products of Cake Hall

 Fruity buns  Rusk

 Baqar khani  Bread

 Shawarma bread  Biscuits

 Sheer mal  Fruit cake

 Muffins  Simple bun

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Images of Cake Hall

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 Cake Hall (Continue…)
Ingredients used in cake hall

• Salt • Murabba

• Flour • Eggs

• Sugar • Oil

• Improver • Ice and water

• Calcium propionate • Leavening agents

• Exotic essence • Color
• Potassium sorbate • Flavor
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 Cake Hall (Continue…)
Fruit Bun

Mixing
Slow 3-4 min Cooling Packaging
Fast 12-14 min

Dividing,
molding, Depanning
Panning

Proofing Baking
35-37°C 210-230°C
90-100 min 14-16 min

Figure 1. Process Flow Diagram of Fruit Bun Making

 Cake Hall (Continue…)
Shawarma bread
Mixing Baking
(slow 2 min, 190-200°C Depanning
fast 15-20 min) 7-8min

Proofing
Moulding Cooling
40-50 min

Sheeting
(Sheeter
Dividing Packaging
machine) and
loading

Figure 2. Process Flow Diagram of Shawarma Bread Making

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 Cake Hall (Continue…)
Baqar khaani
Mixing Cutting , Rolling
Sheeting
10-12 min and pressing

Weighing Baking
Rolling and
Dough wt. 3kg folding 210°C
Margarine puff (Pressing) 45min
wt. 1kg

Molding and
Sheeting Sheeting
(Sheeter machine)

Cream
Folding and
filling(Apply Puff
pressing
on The dough)

Figure 3. Flow Diagram of Baqar Khaani Making 38

 Cake Hall (Continue…)
Sheer maal
Mixing Baking
Slow 3min 180°C DE panning
Fast 28 min 16 min

Molding and
Second proofing Cooling
dividing

Molding
Proofing Packaging
(Manually)

Figure 4. Process Flow Diagram of Sheer Mal

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Cake Hall (Continue…)
Muffins
Mixing
Packaging
15 min

Filling
(pouring mixed De panning
fluid into cups)

Baking
220°C Cooling
13-17 min

Figure 5. Flow Diagram of Muffins Making

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 Burger Hall
Followings are the regular Followings are the type of
customer of dawn burger burgers
• KFC • Burger bun
• OPTP • Junior bun
• Hardees • Minni hoggi
• Fri chicks • Hot dog bun
• FAT restaurant • Hoggi roll
• Johnny Rocket • Bran bun
• Local market • Macroil 41
Images of Burger Hall

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Ingredients used in Burger hall

Flour Oil
Yeast ( AB Maury ) Gluten
Water / ice Till (sesame)
SSL ( sodium sterol lactilate) Ascorbic acid
Sugar (powder form) Burger softener
Improver (wheat flour, soy flour, Salt
enzymes, flour treatment agent E-300) Calcium propionate

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Procedure For Manufacturing of Burger

Fist spongue is Seeding by Baking

made (7min) seeding 10min, 230-
Stay time half machine 250°C
hour

Mixing Final proofing

(45 min, Depaning and
( 14-16 min Humidity 95% cooling
20-21°C ) 35◦C temp)

dividing, Dedusting by
Molding, vacuum Slicing
dusting sucker

Initial
proofing Sheeting and Packaging
loading
(3-4 min)
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 Bread Section

 Flour, water, yeast, sugar and salt are the

four basic ingredients of bread

 Shortening, mineral, vinegar, soya flour, milk powder,

preservatives and fruits are optional

 The different types of breads are

White bread

Atta bread
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Bread Section (Continue…)

Bran bread
Milky bread
Mini bread
Sandwich bread.
It is largest bread
Called as extra-large bread.
It is close top bread
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 Bread Section (Continue…)
 Kinds of mixing
1. Straight dough method
Mixing of all the ingredients at a
time to make dough
Less fermentation time
Less labor cost
Time saving
Less bread flavor and volume
2. Sponge and dough method
Take 1/3 of ingredients and mix
them to make spongue
Leave the spongue for 2-3 hours
After that 2/3 of ingredients are
added and mixed
Then fermentation time is given
10-15 minutes
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 Purposes of Dough Mixing
• Intimate and uniform mixture of the necessary ingredients
• To properly form the smooth glutinous mass called dough
• Complete wetting of the starch
• Insure complete hydration of the gluten
• Promoting its extensibility and palatability which is later perfected by
yeast action
• Completely and uniformly distribute the yeast cells throughout the
dough mass
• Bringing them into intimate contact with the rest of the dough from
which the yeast secures its nutrition
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 Four Stages of Dough Mixing
• Initial Stage:
 Uniform Blending of the Ingredients
 Dough Wet and Sticky
• Pick up Stage:
 Gluten Structure develop
• Clean up stage:
 Dough Become dry and Elastic
 Cohesive Mass is produce which avoid stickiness from the wall
• Development Stage:
 Critical Stage
 Smooth, Dry and Silky Appearance
 Form Smooth and Long Structure
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 Friction factor

• Temperature resulting from the action of kneading or mixing, is

friction factor
• Friction factor refers to the amount of energy or heat generated
during the dough making process
• Friction varies according to whether the action is manual or
mechanical,
• How much time the action takes,
• And the firmness of the dough.
• If the action is mechanical, friction also depends upon the type of
mixer used 50
 Friction factor Continue…
 The general procedure for calculation of friction is given below
Prior to making the dough, note the exact temperature of the room, flour,
and water.
 After the dough is made, note the dough’s temperature
FF = (FDT×3) – (RT+FT+WT)

FF = friction factor

FDT = finished dough temperature

RT = room temperature

FT = flour temperature

 WT= water temperature
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 Friction factor Continue…
I calculated friction factors for various batches. Some examples are given

below.

For large bread

RT = 28.5ºC

FT = 26.5ºC

WT = 5.5ºC

FDT= 26.5ºC

FF = (26.5×3) – (28.5+26.5+5.5)=79.5 – 60.5 = 19ºC

• 

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 Friction factor Continue…

For medium bread

RT = 28ºC

FT = 26.5ºC

WT = 6ºC

FDT= 27ºC

FF = (27×3) – (28+26.5+6)

= 81 – 60.5

= 20.5ºC
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 Friction factor Continue…

 For standard bread

RT = 29ºC

FT = 27ºC

WT = 6ºC

FDT= 25ºC

FF = (25×3) – (29+27+6)

= 75 – 62

= 13ºC
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 Friction factor Continue…

 For mini bread

RT = 28.5ºC

FT = 25ºC

WT = 5ºC

FDT= 26ºC

FF = (26×3) – (28.5+25+5)

= 78 – 58.5

= 19.5ºC
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 Study the Indication of Completion of Mixing

 Proper mixing is very important to obtain good quality end product

 Under or over mixing will result in poor quality bread.
 Completion of mixing is checked by using window test.
 Procedure of checking the mixing indication is given below.
 Pinch off a piece of dough
 Using both hands, grasp opposite sides of the piece of dough with
your fingertips
 Slowly pull your hands apart and stretch the dough by approx. 3 -
5cm
 Dough should look like a window with a thin membrane in the center
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 Continue…

 Stop kneading
If the dough forms a window-like membrane and stretches
without breaking.
 Keep kneading
If the dough doesn't stretch easily and tears, continue
kneading

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 Manufacturing process of Bread

Initial proofing
weighing of Sheeting and
28-30°C molding Packaging
ingredients
10min

Cutting by Depaning and

Shifting Dusting cutters cooling

Baking
shifted to the Panning
Mixing 215-220°C
rounder (greased pans)
28-30min

Loading of weighing of Final proofing

dough balls Loading into
dough into 75-85min
trays
divider/hopper 35-37°C
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 Baking Report
Temperature

S.no Bread Type RPM Time (min)

A-Zone B-Zone
1 Standard Milky 299-330 36 225 200

2 Simple Large 290-330 40 203 202

3 Simple O.T 325-400 34 200 204
4 Milky Small 288-290 40 196 200
5 Medium Bread 290-310 40 195 198
6 Medium Bread 290 36 194 198
7 Bran Bread 380 25 206 211

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 Baking Report Continue…
S.# Bread Type RPM Time (min) Temperature

A-Zone B-Zone
8 Milky Standard 290 37 191 200

9 Simple Large 290 37 191 196

10 Sandwich Bread 290 37 203 201

11 Milky Large 290 38 202 207

13 Milky O.T 300 37 200 212

14 Milky Standard 300 36 200 210

15 Small Rusk 450 25 200 208

16 Small Rusk 450 25 198 216

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 Bread Baking Problems

 Too high and low oven temperature

 Too low rise in loaf
 Not enough yeast
 Too much salt in the recipe
 Too much sugar in dough
 Under proofing or too short final rise of loaf
 Over proofing or too long final rise time
 Too high oven temperature

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Bread Baking Problems Continue…
 Too much expansion in dough
 Not enough salt in the dough
 Dough baked before it had finished proper proofing
 Loaves too large for pan
 Under mixed or under developed dough
 Over proofing
 Too dark crust
 Baking too long
 Too much sugar in the recipe

 Too pale crust 62

 Suggestions
 Hygiene of workers should be maintained

 Sanitization of industry should be done

 Industry should have its own ambulance and first aid facilities

 Industry should develop research laboratories

 Timely presence of workers and management persons

 Appraisal must be done in different forms

 Time wastage should be avoided

 Keep an eye on every task and production line

 Every one should be allowed to give innovative idea

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